2007 Ski-Doo REV Series Shop Manual | GSX, GTX, MX Z, and Summit Snowmobiles

Ski-Doo REV Series Shop Manual - 2007 Edition

This official factory service documentation provides technical directives for the maintenance and repair of 2007 REV Series snowmobiles. It specifically addresses critical uptime requirements, such as the mandatory periodic lubrication of the rewind starter spring with Molykote PG 54 to prevent component failure in sub-zero temperatures.

Chassis Configuration & Powertrain Applicability

REV Series Chassis: 552 Fan-Cooled Powertrains

• GSX Fan (2007)
• GTX Fan (2007)
• MX Z 550 X (2007)
• MX Z Fan (2007)
• SUMMIT Fan (2007)

REV Series Chassis: 593/793/797 Liquid-Cooled Powertrains

• GSX Sport (2007)
• GSX Limited (2007)
• GTX Sport (2007)
• GTX Limited (2007)
• MX Z Adrenaline (2007)
• MX Z Blizzard (2007)
• MX Z Renegade / Renegade X (2007)
• MX Z Trail (2007)
• MX Z X / XRS (2007)
• SUMMIT Adrenaline (2007)
• SUMMIT X / XRS (2007)

Operational Performance & Reliability Benchmarks

• Precision calibration data for SDI and Power TEK engine management systems ensures optimal fuel delivery and emissions compliance.
• Step-by-step diagnostic flow charts facilitate rapid troubleshooting of electrical and engine management faults using B.U.D.S. software.
• Verified torque sequences for critical fasteners mitigate the risk of engine base leaks and structural fatigue during high-load operation.

Document Metadata

• Manual Type: Shop Manual
• Print Number: mmr2007-002
• Total Pages: 650+
• Primary Vehicle Category: Snowmobile

System Architecture & Factory Benchmarks

Fastener Integrity & Tension Specifications Standard metric fasteners require strict adherence to property class torque limits to prevent hardware failure.

• M6 (8.8 Grade): 10 N·m (89 lbf·in)
• M8 (8.8 Grade): 24.5 N·m (18 lbf·ft)
• M10 (8.8 Grade): 48 N·m (35 lbf·ft)
• Engine Support Bolts: 38 N·m (28 lbf·ft) using Loctite 222

Fluid Capacities & Lubricant Standards

• Chaincase (Fan Cooled): XP-S chaincase oil (P/N 413 801 900)
• Chaincase (Liquid Cooled): XP-S synthetic chaincase oil (P/N 413 803 300)
• Brake System: DOT 4 Brake Fluid only
• Engine Injection: BRP XP-S injection oil

Technical Navigation & Diagnostic Schematics

Detailed exploded views provide visual confirmation of component orientation, including specific Loctite application zones and specialized tool interface points. The manual includes dedicated sections for:

• EMS Fault Code Supplemental Information
• Engine Leak Verification Flow Charts
• Wiring Diagram Legends and Sumitomo/Deutsch Connector Pinouts

Table of Contents

• Maintenance: Maintenance Chart, Storage Procedures, Preseason Preparation
• Troubleshooting: Engine, Fuel/Oil Systems, Drive System, Electrical, Steering, Suspension
• Engine: Removal/Installation (552/593/793/797), Leak Test, Air Intake, Exhaust, Rewind Starter
• Cooling System: Axial Fan (552), Liquid Cooling (593/793/797)
• Engine Management: Power TEK and SDI Systems
• Electrical System: Ignition, Charging, Starting, DESS, RER, Lights/Instruments
• Drive System: Drive/Driven Pulleys, Alignment, Chaincase, Drive Axle, Track
• Chassis: Front/Rear Suspensions (SC-10, SC-4), Steering, Body/Frame
• Technical Specifications: Comprehensive engine and vehicle data

Operational Limits & Critical Clearances

• Engine Pressurization: 34 kPa (5 PSI) for 3 minutes during leak testing.
• Drive Belt Wear Limit: Replace if width decreases by 3 mm (1/8 in) from nominal.
• Coolant Level (Cold): 15 mm (5/8 in) over the COLD level line.
• Throttle Body Maintenance: Use pulley flange cleaner (P/N 413 711 809) for SDI throttle plate bores.